Frameless Electrochemical Cell Design for Reduced Resistance
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Solution Overview
Problem
Current electrochemical cell technologies, such as fuel cells, electrolyzers, and redox flow batteries, face high system and storage costs due to complex manufacturing processes and material usage, particularly in frame and sealing materials, which limit electrode thickness and increase electrical resistance and pressure losses, hindering market penetration and efficiency.
Innovation Solution
A frameless cell and stack design with a flat structure that allows for variable electrode thickness and compression, decouples electrode permeability from pressure loss, and optimizes flow paths to minimize IR and pressure losses, enabling homogeneous electrolyte distribution and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If frame and sealing materials are used in conventional electrochemical cell design, then structural support and sealing are achieved, but manufacturing costs increase and electrode thickness is limited
Solution Approach 1:
The patent merges the frame, sealing, and electrode support functions into a single integrated membrane electrode assembly structure. The membrane itself serves as both the separator and the structural element that provides support, eliminating the need for separate frame and sealing materials. This integration reduces manufacturing costs while maintaining the necessary structural integrity.
Solution Approach 2:
The patent extracts and eliminates the frame and sealing materials from the conventional cell design. By removing these separate components and their associated manufacturing processes, the design achieves lower manufacturing costs while the membrane electrode assembly provides the necessary structural support through its own reinforced structure.
2Reliability
If conventional frame structures are used, then cell assembly is maintained, but electrical resistance and pressure losses increase
Solution Approach 1:
The patent extracts and removes the conventional frame structure from the cell design. By eliminating the frame, the design reduces electrical resistance pathways and pressure losses that were introduced by frame components. The membrane electrode assembly itself provides the necessary structural support without the intermediary frame structure.
Solution Approach 2:
The patent combines the structural support function previously provided by the frame into the membrane electrode assembly. This integration eliminates the additional electrical resistance and pressure losses that occur at the interfaces between frame and electrode components, resulting in improved electrical conductivity and reduced pressure drops.
3Productivity
If electrode thickness is limited by frame structures, then assembly is simplified, but power density decreases
Solution Approach 1:
The patent extracts the frame structure that was limiting electrode thickness. Without the frame constraints, electrodes can be made thicker to increase active material content and power density, or thinner to reduce resistance, depending on the specific design requirements. The membrane electrode assembly provides support without imposing thickness limitations.
Solution Approach 2:
The patent enables dynamic optimization of electrode thickness by removing the fixed constraints imposed by frame structures. The membrane electrode assembly allows electrode thickness to be adjusted based on performance requirements, enabling optimization for either high power density (thicker electrodes) or low resistance (thinner electrodes) without assembly complications.
4Ease of manufacture
If frame and sealing materials are used, then cell integrity is maintained, but material usage and costs increase
Solution Approach 1:
The patent merges the sealing and structural functions into the membrane electrode assembly itself. The membrane provides both the sealing barrier and the structural integrity previously requiring separate frame and sealing materials. This integration reduces material usage while maintaining cell integrity through the inherent properties of the membrane electrode assembly structure.
Solution Approach 2:
The patent extracts and eliminates frame and sealing materials from the design. By removing these separate components, material usage and manufacturing costs are reduced. The membrane electrode assembly provides the necessary cell integrity through its own reinforced structure and sealing capabilities without requiring additional frame materials.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design reduces manufacturing costs, increases power and current densities, and enhances energetic and system efficiency by minimizing electrical resistance and pressure losses, while allowing for larger electrode areas and improved electrolyte distribution.
Implementation Method 1
The protons enter the cathode space via the ion exchange membrane
Implementation Method 2
At the anode, the fuel is catalytically oxidized to protons by releasing electrons
Implementation Method 3
A fuel cell converts chemical energy from a continuously supplied fuel and an oxidizing agent into electrical energy
Implementation Method 4
During electrolysis, a redox reaction is forced using an electric current
Data Source
Figure 1~3
Figure 4~5
Figure 6~8
AI summary
The invention relates to an arrangement of electrochemical cells which are operated at a temperature of maximally 300 °C. At least one electrochemical cell is formed with multiple base elements (GE-X) which are arranged one over the other and the outer edge regions of which are connected in a fluid-tight manner; two electrodes; one membrane; at least two respective inlets and outlets; and at least two regions through which reactants can flow and each of which contacts one of the two electrodes. The base elements (GE-X) are partly provided with at least one filling compound (FM-Y) in some regions, said regions forming a seal and/or a membrane and/or an electrode and/or a bipolar plate made of film together with the base element (GE-X). Some of the regions are provided without the filling compound (FM-Y), said regions functioning as spacers between functional materials and/or functional elements and being fluidically permeable for the reactants on or perpendicular to the plane of the base elements (GE-X), thus forming defined flow paths for the reactants. Some regions are also provided with through-holes that form fluid inlets and outlets, channeling and distributing structures, and the regions through which reactants can flow, and/or the through-holes constitute receiving areas for functional materials, such as membranes, electrodes, through or over which the fluid can flow, and bipolar plates or films and/or functional elements, and/or an additional filling compound (FM-Y) can be arranged or introduced into said through-holes.